MEMO

505CH2 maintenance tools and guidelines

Rev 0- September 2015

1. CMM access All the Saft technical documentation and the CMM of the 505CH2 battery are available on our website:
http://aircraft.saftbatteries.com/MarketSegments/Aircraft/TechnicalDocumentation/tabid/443/
Language/en-US/Default.aspx
• OMM - CMM
• Material Safety Data Sheet
• Service bulletin / Service information letter / Temporary revision
• Technical note
• Certificates / Eligibility list
The search engine allows you to search either using the battery description or by aircraft. Also, the
right hand side of the page contains the CMM and OMM information in the old format. So you have
several possibilities of searching.

1.1. Saft Aviation Update
Service
If you would like to receive automatic e-mails when new technical documentation is available, please
subscribe to the Saft Aviation Update Service by filling out the registration form at:
http://aircraft.saftbatteries.com/MarketSegments/Aircraft/Subscribe/tabid/444/Language/en-US/
Default.aspx
This service is completely free of charge and can be terminated at any time.

2. Saft training
As a service to our customers, the Saft Aviation Battery Maintenance Training (BMT) aim is to provide
general guidance and instructions, to enable operators to perform an efficient Saft nickel-cadmium
battery fleet management. It should provide customers with an increased service life and reduced
operational costs, via adequate maintenance and repair tasks planning and execution.
Our trainers are very high skilled engineer working in aviation batteries for years. Our customers over
the world have expressed their satisfaction and recognized the benefit from the training in their day
to day maintenance task on Saft batteries.
The BMT learning objectives for the maintenance/operators staff are:
• To enable customers to identify the circumstances, preliminary investigations results that
may require Saft assistance, technical expertise and/or it's approved repair network inter-
vention (return for repair and/or expertise request),
• To learn fundamentals on one side and specific details on another side of Saft aviation bat-
tery features and benefits,
• To acquire the maximum autonomy in the maintenance and repair operations while applying
Saft component maintenance manual (CMM) or operating maintenance manual (OMM) ins-
tructions.
Over two complete days, the BMT training program includes:
• Basic Ni-Cd battery electrochemistry,
• Ni-Cd operational characteristics,
• Hands on,
• Aviation battery troubleshooting, safety and environmental instructions,
• A comprehensive review of recommended battery maintenance instructions.
All the information are available on our website at: http://www.saftbatteries.com/support-services/
training/li-ion-battery-training-lbt

Copyright © Saft 1999, 2015 page 1/4

SAFT FRANCE 12 rue Sadi Carnot 93170 Bagnolet France - Tel: (33) 1 49 93 19 18 - Fax: (33) 1 49 93 19 56
SAFT AMERICA INC. 711 Industrial Blvd. Valdosta, GA 31601 - Tel: (1) (229) 247 2331 - Fax: (1) (229) 247 8486
www.saftbatteries.com
Rev 0- September 2015
3. Maintenance good
practices reminder
3.1. SIL0111 reminder:
3.2. OPH/FH calculation
reminder:
3.3. Topping-up
3.4. Torque check
Copyright © Saft 1999, 2015
SAFT FRANCE 12 rue Sadi Carnot 93170 Bagnolet France - Tel: (33) 1 49 93 19 18 - Fax: (33) 1 49 93 19 56
SAFT AMERICA INC. 711 Industrial Blvd. Valdosta, GA 31601 - Tel: (1) (229) 247 2331 - Fax: (1) (229) 247 8486
505CH2 maintenance tools and guidelines
In order to optimize battery life and performance the following Memo has been generated. This memo
reminds the procedure as presented in the various CMM's and OMM.
REGULAR GENERAL
BATTERY CMM AIRCRAFT PERIODICAL CHECK
CHECK OVERHAUL
505CH2 24-38-55 A380 According to con- 3000oph 12 months
sumption (see CMM)
OPERATING HOURS means the sum of the flight and ground operation time when the battery is
connected to the aircraft network. The ratio of operating hours (oph) to flying hours (fh) depends
on the operator. It is generally in the range of 1.2 for long range operation to 2 for short haul
operation.
Example for long range operation:
• 2500fh x 1.2 = 3000oph
• 3000oph / 1.2 = 2500fh
Example for short haul operation:
• 1500fh x 2 = 3000oph
• 3000oph / 2 = 1500fh
Electrolyte level adjustment is to be done during the last 15-30 minutes of the 4 hours
overcharge at 0.1C1A. This is determined by accomplishing the following steps:
a) Insert the syringe and nozzle assembly into the cell and pull back on the plunger. If fluid is
pulled into the syringe, there is no need to add any additional distilled or de-ionized water
into the cell. Document the amount of fluid removed from the cell.
b) If, after pulling back on the plunger, there is no fluid in the syringe, inject a measured
amount (5 ml -10 ml) of distilled or de-ionized water into the cell. Repeat this step until fluid
is pulled back into the syringe assembly. Record the amount of water added to the cell.
c) Proceed to the next cell and repeat previous steps a) and b).
Failure to follow the procedures of the CMM may result in decreased battery performance or battery
life.
Battery 505CH2 - CMM 24-38-55 pages 5003 to 5005
In order to reinforce the need to verify correctly the tightening of connector nuts / screws the following
memo has been generated. This reinforcement is to avoid the risk of reduced performance due to
poor contact and of gas ignition due to arcing inside the battery
Whether or not the battery has been subject to disassembly and reassembly, before to be release into
service and installation, the tightness of all connector nuts / screws must be checked to verify that
torque values correspond with those specified in the appropriate CMM.
Battery 505CH2 - CMM 24-38-55 page 8001
page 2/4
www.saftbatteries.com
Rev 0- September 2015
3.5. Corrosion
3.6. Temperature sensor
test and repair
3.7. Battery end of life
Copyright © Saft 1999, 2015
SAFT FRANCE 12 rue Sadi Carnot 93170 Bagnolet France - Tel: (33) 1 49 93 19 18 - Fax: (33) 1 49 93 19 56
SAFT AMERICA INC. 711 Industrial Blvd. Valdosta, GA 31601 - Tel: (1) (229) 247 2331 - Fax: (1) (229) 247 8486
505CH2 maintenance tools and guidelines
Saft Ni-Cd battery hardware (nuts, washers, terminals) is made of nickel plated copper which may be
subject to oxidation. Saft recommends that they be lightly coated with neutral petroleum jelly
corresponding to the following Saft part numbers (SFr P/N 203212 or SAI P/N 093448-000).
Equivalent alternatives consumables can be used for petroleum jelly.
DESIGNATION AND SPECIFICATION MANUFACTURER
OR SUPPLIER
Neutral petroleum jelly Mineral Vaseline:
Density @ 60°C (140°F) Range = 0.840 - 0.866 Kg/L OTAN: S 743
Melting Point Range = 46°C - 52°C (115°F - 126°F) F: AIR 3565
Acidity/Alkalinity = Neutral to Litmus US: VV-P-236/A
UK: DEF 2333
Battery 505CH2 - CMM 24-38-55 pages 7005, 8001, 9004, 15002
Sensors are considered as non-repairable items and, as such, must be replaced in the event of any
type of failure.
Check methodology:
• Temperature sensor must be tested during the battery Overhaul. The values must be re-
corded. Check the circuit continuity with a ohmmeter. For precise measurement Saft recom-
mends controlled conditions such as a climatic chamber.
• The insulation of the sensor must be also carried, this one must be performed between each
pins and the battery box with a megohmeter at 250 VDC.
Not to pull / stress the wires of the sensor assembly when assembling / dissasembling it
We have appointed three Partner/Distributors (Aviall, D+C Airparts & Satair) that will help you by
providing other alternative tools for temperature sensor testing.
Battery 505CH2 - CMM 24-38-55 pages 1003, 1004, 1005, 2001, 5011
The end of life depends on criteria as defined in the CMM. If one of the following steps failed, the cell
of the battery shall be scrapped.The main criteria for end of cell life are:
3.7.1. Capacity
This is a measure of separator membrane metallization. During battery life, the cadmium metallization
of the membrane is progressive according to temperature, amount of overcharge and charge current
quality. At end of life the metallization prevents full charge being reached leading to reduced capacity.
Battery 505CH2 - CMM 24-38-55 pages 1011, 5004 to 5011
3.7.2. The end of charge voltage
This is a measure of the separator degradation. During battery life, degradation of the separator is
progressive and is accelerated at high temperature and high amounts of overcharge. As this it
degrading, the oxygen evolved in overcharge process where the oxygen can more readily go to the
negative electrode where it is recombined, leading to heat generation and reduced voltage under
constant current charge or increased overcharge current under constant voltage charge.
Battery 505CH2 - CMM 24-38-55 pages 1010, 5004 to 5011
3.7.3. The topping-up above the maximum
This is a measure of the cell degradation due to charge exceeding the limit or too much charge at high
temperature. As this is degrading the cell performances and drying of the cell, this induces heat
generation.
Battery 505CH2 - CMM 24-38-55 pages 5003 To 5005
page 3/4
www.saftbatteries.com
Rev 0- September 2015 505CH2 maintenance tools and guidelines

PAGE INTENTIONALLY LEFT BLANK

Copyright © Saft 1999, 2015 page 4/4

SAFT FRANCE 12 rue Sadi Carnot 93170 Bagnolet France - Tel: (33) 1 49 93 19 18 - Fax: (33) 1 49 93 19 56
SAFT AMERICA INC. 711 Industrial Blvd. Valdosta, GA 31601 - Tel: (1) (229) 247 2331 - Fax: (1) (229) 247 8486
www.saftbatteries.com